Gradient printing a three-dimensional structural component

This application is a continuation of U.S. patent application Ser. No. 18/179,313, filed Mar. 6, 2023, now U.S. Pat. No. 11,938,672, which is a continuation of U.S. patent application Ser. No. 16/823,537, filed Mar. 19, 2020, now U.S. Pat. No. 11,618,206, which is a continuation of U.S. patent application Ser. No. 15/609,205, filed May 31, 2017, now U.S. Pat. No. 10,596,753, which claims the benefit of U.S. Provisional Patent Application No. 62/343,757, filed May 31, 2016, each of which is incorporated by reference herein in their entirety.

Embodiments relate generally to printing UV-curable graphic layers on bases such as the fabric used to make articles of apparel such as shirts, shorts, pants, jackets, hats or caps, or to make uppers for articles of footwear, such as running, training, jogging, hiking, walking, volleyball, handball, tennis, lacrosse, basketball shoes, and other similar articles of footwear, as well as to make other articles such as backpacks or tents.

Articles of apparel may be made of a woven or nonwoven fabric, or of a mesh material, or may be made of leather, synthetic leather, or of plastic materials. Articles of apparel may have items such as emblems or logos on the sleeves, torso, pants leg, or other portions of the article of apparel. Articles of apparel may also have abrasion-resistant, water-resistant or protective layers at, for example, the elbows, the shoulders, and/or the knees.

Printers or plotters may be programmed to deposit layers of acrylic resin ink, polyurethane ink, TPU ink or silicone ink or other inks on a fabric or other article. Such printers or plotters may be programmed to cover a two-dimensional portion of a fabric, for example, by moving a printhead along a track in a first direction and moving the track in a second direction that is orthogonal to the first direction. Other printers or plotters may move the printhead in a first direction while moving the printer platform in a second direction that is orthogonal to the first direction, or may move the platform in both directions while keeping the printhead stationary.

For clarity, the detailed descriptions herein describe certain exemplary embodiments, but the disclosure in this application may be applied to any method for fabricating an article including any suitable combination of features described herein and recited in the claims. In particular, although the following detailed description describes certain exemplary embodiments, it should be understood that other embodiments may be used for the fabrication of other articles of footwear or apparel.

As used herein, the terms “printing device,” “printer,” “plotter,” “3D printer,” “three-dimensional printing system,” or “3D printing system” may refer to any type of system that can print multiple layers onto a fabric, an article of footwear, an article of apparel or other article, including, for example, sign and graphics printers. The printers may use any appropriate type of UV-curable ink, including acrylic resin ink, polyurethane ink, TPU ink or silicone ink or any other appropriate ink.

In one aspect, a method of printing a three-dimensional structural component onto a base is provided. The method includes receiving a set of predetermined thicknesses for the three-dimensional structural component. The set of predetermined thicknesses has a first thickness and a second thickness. The first thickness is greater than the second thickness. The method includes instructing a printing device to print a single layer for the three-dimensional structural component using the set of predetermined thicknesses. The method includes printing a first portion of the single layer onto the base so that the first portion has the first thickness. The method includes printing a second portion of the single layer onto the base so that the second portion has the second thickness.

In another aspect, a method of printing a three-dimensional structural component onto a base is provided. The method includes receiving a set of predetermined thicknesses for the three-dimensional structural component. The set of predetermined thicknesses has a first thickness corresponding to a first position of the base and a second thickness corresponding to a second position of the base. The first thickness is greater than the second thickness. The method includes instructing a printing device to print a set of layers of the three-dimensional structural component using the set of predetermined thicknesses. The set of layers includes at least a first layer and a second layer. The method includes printing the first layer of the three-dimensional structural component directly onto the base using the set of predetermined thicknesses. Printing the first layer includes printing the first layer to have the first thickness at the first position of the base. Printing the first layer includes printing the first layer to have the second thickness at the second position of the base. The method includes printing the second layer of the three-dimensional structural component directly onto the first layer using the set of predetermined thicknesses. Printing the second layer includes printing the second layer to have the first thickness at the first position of the base. Printing the second layer includes printing the second layer to have the second thickness at the second position of the base.

In another aspect, a method of printing a three-dimensional structural component onto a base is provided. The method includes receiving a set of predetermined thicknesses for the three-dimensional structural component. The method includes instructing a printing device to print a set of layers of the three-dimensional structural component onto the base. The method includes printing the three-dimensional structural component onto the base using the set of predetermined thicknesses to form a printed set of layers. Printing the three-dimensional structural component includes printing a first layer of the set of layers directly onto the base. A separation distance between the base and a printhead assembly of the printing device remains constant during the step of printing the first layer of the set of layers directly onto the base. The printed set of layers includes an exposed surface of the three-dimensional structural component. The exposed surface includes a tall region, an intermediate region, and a short region. The intermediate region abuts the tall region. The intermediate region abuts the short region. A difference in height between the tall region of the exposed surface and the short region of the exposed surface is greater than the separation distance. The intermediate region of the exposed surface has a smoothly sloped geometry.

Other systems, methods, features, and advantages of the embodiments will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description and this summary be within the scope of the embodiments.

Although the drawings and the textual description herein only describe embodiments as they may be used on certain articles of footwear or certain articles of apparel, the descriptions herein may also be applied to other articles of footwear and/or to other articles of apparel, including, for example, articles of footwear such as running, training, jogging, hiking, walking, volleyball, handball, tennis, lacrosse, basketball shoes and other similar articles of footwear, or articles of apparel such as shorts, shirts, jerseys, jackets, pants, gloves, wrist bands, headbands, armbands, hats or caps, as well as to other articles such as backpacks or tents.

is a schematic view of an embodiment of three-dimensional printing system, also referred to simply as printing system. Some embodiments of the printing system can include provisions that distribute one or more functions among different devices of the printing system. As shown, printing systemmay include printing device, computing system, and network. In other embodiments, the printing system may be a single device or component (not shown).

Some embodiments of the printing device can include provisions that permit color printing. In some embodiments, the printing system may use CMYK printing. In other embodiments, the color printing may be conducted using another suitable printing method.

In embodiments where color printing is conducted using CMYK printing, any suitable device, protocol, standard, and method may be used to facilitate the color printing. As used herein, “CMYK” may refer to four pigments used in color printing: “C” for a cyan pigment, “M” for a magenta pigment, “Y” for a yellow pigment, and “K” for a key pigment. In some cases, the key pigment may be a black pigment. An example of a printing device using CMYK printing is disclosed in Miller, U.S. Patent Publication No. 2015-0002567, published on Jan. 1, 2015, titled “Additive Color Printing” (U.S. patent application Ser. No. 13/927,551, filed on Jun. 26, 2013), which application is herein incorporated by reference and referred to hereafter as the “Color Printing” application. In some embodiments, printing systemcan include one or more features of the systems, components, devices, and methods disclosed in the Color Printing application to facilitate color printing. For example, the printing device may be configured to print an image by dispensing droplets of a print material including one or more pigments onto a base. As used herein, droplets may refer to any suitable volume of print material. For example, a droplet may be 1 milliliter of print material. In other embodiments, the printing system may use other systems, components, devices, and methods.

In embodiments where the printing system includes provisions that distribute one or more functions among different devices of the printing system, any suitable division may be used. In some embodiments, printing systemcan include provisions that control and/or receive information from printing device. These provisions can include computing systemand network. Generally, the term “computing system” refers to the computing resources of a single computer, a portion of the computing resources of a single computer, and/or two or more computers in communication with one another. Any of these resources can be operated by one or more human users. In some embodiments, computing systemmay include one or more servers. In some embodiments, a print server may be primarily responsible for controlling and/or communicating with printing device, while a separate computer (e.g., desktop, laptop, or tablet) may facilitate interactions with a user. Computing systemcan also include one or more storage devices including, but not limited to, magnetic, optical, magneto-optical, and/or memory, including volatile memory and non-volatile memory.

In some embodiments, any suitable hardware or hardware systems may be used to facilitate provisions that control and/or receive information from printing device. In some embodiments, where a computing system is used, computing systemmay include central processing device, viewing interface(e.g., a monitor or screen), input devices(e.g., keyboard and mouse), and software for creating set of predetermined thicknessesfor printing a three-dimensional structural component. As used herein, a set of predetermined thicknesses may include any suitable information to facilitate formation of a three-dimensional structural component to have a shape represented by the set of predetermined thicknesses. Examples of shapes represented by a set of predetermined thicknesses may include cylinder, cone, cube, sphere, and the like. In some instances, the set of predetermined thicknesses may be personalized for a particular customer. In other embodiments, other forms of hardware systems may be used.

Generally, any suitable information may be used to facilitate provisions for software for designing a set of predetermined thicknesses for a three-dimensional structural component. In at least some embodiments, software for designing a set of predetermined thicknesses of a printed structure may include not only information about the geometry of the structure but also information related to the materials required to print various portions of the component. In other embodiments, different information may be used.

Generally any suitable design structure may be used to transform the design into information that can be interpreted by printing device(or a related print server in communication with printing device). In some embodiments, printing systemmay be operated as follows to provide one or more components that have been formed using a three-dimensional printing, or additive process. Computing systemmay be used to design a structure. This may be accomplished using some type of CAD software or other kind of software. The design may then be transformed into information that can be interpreted by printing device(or a related print server in communication with printing device). In some embodiments, the design may be converted to a three-dimensional printable file, such as a stereolithography file (STL file); in other cases, the design may be converted into a different design component.

In some embodiments where the printing system includes provisions that distribute one or more functions among different devices of printing system, any suitable protocol, format, and method may be used to facilitate communication among the devices of printing system. In some embodiments, these communications are conducted using network. In other cases, these communications may be conducted directly between devices of printing system.

In some embodiments, the network may use any wired or wireless provisions that facilitate the exchange of information between computing systemand printing device. In some embodiments, networkmay further include various components such as network interface controllers, repeaters, hubs, bridges, switches, routers, modems, and firewalls. In some embodiments, networkmay be a wireless network that facilitates wireless communication between two or more systems, devices, and/or components of printing system. Examples of wireless networks include, but are not limited to, wireless personal area networks (including, for example, BLUETOOTH), wireless local area networks (including networks utilizing the IEEE 802.11 WLAN standards), wireless mesh networks, mobile device networks as well as other kinds of wireless networks. In other cases, networkcould be a wired network including networks whose signals are facilitated by twister pair wires, coaxial cables, and optical fibers. In still other cases, a combination of wired and wireless networks and/or connections could be used.

Some embodiments of the printing system can include provisions that permit printed structures to be printed directly onto one or more articles. The term “articles” is intended to include both articles of footwear (e.g., shoes) and articles of apparel (e.g., shirts, pants, etc.). As used throughout this disclosure, the terms “article of footwear” and “footwear” include any footwear and any materials associated with footwear, including an upper, and may also be applied to a variety of athletic footwear types, including baseball shoes, basketball shoes, cross-training shoes, cycling shoes, football shoes, tennis shoes, soccer shoes, and hiking boots. As used herein, the terms “article of footwear” and “footwear” also include footwear types that are generally considered to be nonathletic, formal, or decorative, including dress shoes, loafers, sandals, slippers, boat shoes, and work boots.

While the disclosed embodiments are described in the context of articles of footwear, various embodiments may further be equally applied to any article of clothing, apparel, or equipment that includes three-dimensional printing. For example, various embodiments may be applied to hats, caps, shirts, jerseys, jackets, socks, shorts, pants, undergarments, athletic support garments, gloves, wrist/arm bands, sleeves, headbands, any knit material, any woven material, any nonwoven material, sports equipment, etc. Thus, as used herein, the term “article of apparel” may refer to any apparel or clothing, including any article of footwear, as well as hats, caps, shirts, jerseys, jackets, socks, shorts, pants, undergarments, athletic support garments, gloves, wrist/arm bands, sleeves, headbands, any knit material, any woven material, any nonwoven material, and the like.

Referring to, which shows an embodiment including set of articles, in other embodiments, different articles may be used. As shown, set of articlesincludes article of footwear, shin guard, and article of apparel. In other embodiments, set of articlesmay be different.

Generally, any suitable surface of the article may be used as a base to receive the three-dimensional objects. In some embodiments, the article includes a surface in a flattened configuration. Referring to, shin guardmay have a front surface and/or a back surface in a flattened configuration. In another example, article of apparelmay have a front surface and/or a back surface in a flattened configuration. In other embodiments, an article may include a surface having a three-dimensional configuration. For example, a side surface of article of footwearmay have a three-dimensional configuration. In another example, a top surface of shin guardmay have a three-dimensional configuration. In other embodiments, the printing device and/or printing system may print onto other surfaces.

Some embodiments of the printing system can include provisions that permit printing directly onto the article. In other cases, the three-dimensional structural component is first printed onto a release layer and then transferred onto the article.

In some embodiments any suitable material may be used to form the article to facilitate use of the article. In some embodiments, printing devicemay be capable of printing onto the surfaces of various materials such as a textile, natural fabric, synthetic fabric, knit, woven material, nonwoven material, mesh, leather, synthetic leather, polymer, rubber, and foam, or any combination of them, without the need for a release layer interposed between a base and the bottom of the print material, and without the need for a perfectly or near perfectly flat base surface on which to print.

In some embodiments, the articles may be customizable. As used herein, a customizable article may be preprocessed and unfinished. Referring to, the processing of article of footwearmay include cutting an upper in a particular shape and/or treating the upper to improve durability for use as footwear. In some examples, the upper may be folded and attached to a sole. In other examples, the upper may be in a flat configuration (see). In the example of, article of footwearmay not be finished with a mass production design. Instead, article of footwearmay be suitable for finishing with a personalized three-dimensional structural component for a particular customer.

Some embodiments of the printing device may include provisions that permit the printhead assembly to be moved across the base to facilitate printing of features, such as images, graphics, designs, and text onto the base. In some embodiments, the printing device may move the printhead assembly along the base. In other embodiments, the printing device may move the base in relation to the printhead assembly.

In embodiments where the printing device moves the printhead assembly, the printing device may move the printhead assembly in a direction parallel to any suitable number of axes. In some embodiments, the printing device may move the printhead assembly along a printing surface. Referring to, printing devicemay move printhead assemblyalong baseto facilitate a printing onto base. In the example, printing devicemay move printhead assemblyparallel to first axisand/or parallel to second axis. As shown, first axismay extend parallel to baseand/or perpendicular to second axis. In the example, second axismay extend parallel to baseand/or perpendicular to first axis. In some embodiments, the printing device may raise or lower the printhead assembly. Referring to, printing devicemay raise or lower printhead assemblyalong third axis. As shown, third axismay be normal to baseand perpendicular to first axisand/or second axis. In other embodiments, the printing device may move the printhead assembly relative to the base differently.

In embodiments where the printing device moves the base, the printing device may move the base in a direction parallel to any suitable number of axes. In some embodiments, the printing device may move the base horizontally with the printhead assembly. Referring to, printing devicemay move baseparallel to first axisand/or parallel to second axis. In some embodiments, the printing device may move the base vertically with the printhead assembly. Referring to, printing devicemay raise or lower baserelative to printhead assemblyin a direction parallel with third axis. In other embodiments, the printing device may move the base relative to the printhead assembly differently.

In some embodiments, the printhead assembly may be moved along a continuous printing path to facilitate printing a single layer onto the entire surface of the base. Referring to, printing devicemay print along continuous printing path. In the example, printhead assemblymay initially be positioned at left edgeof baseand at top edgeof base. In the example, printhead assemblymay be moved relative to base along one direction (e.g., right) of second axisuntil the printhead assemblyis positioned at right edge. In the example, printhead assemblymay subsequently be moved relative to base along one direction (e.g., down) of first axistoward bottom edgeof baseand then moved relative to basealong the other direction (e.g., left) of second axisuntil the printhead assemblyis positioned at left edge. In this manner, printhead assemblymay continuously dispense print material onto an entire upper surface of base. In other embodiments, the printhead may be moved along the base differently to facilitate printing on the entire surface of the base.

Some embodiments of the printing device may include provisions that permit the printhead assembly to print in both directions along an axis to facilitate printing along a continuous printing path. In some embodiments, the printhead assembly may include a curing device for printing along one direction (e.g., right) parallel to an axis and a curing device for printing along the other direction (e.g., left) parallel to an axis. Referring to, printhead assemblymay include curing device, which may emit ultraviolet lightas printhead assembly moves along one direction (e.g., right) parallel to second axis. In the example, printhead assemblymay include curing device, which may emit ultraviolet lightas printhead assembly moves along the other direction (e.g., left) parallel to second axis. In other embodiments, a single curing device may be used or more than two curing devices may be used to facilitate printing along a continuous printing path.

shows a block diagram of a process for printing a three-dimensional structural component onto a base, in accordance with an exemplary embodiment. The various steps ofmay be discussed with respect to. In some embodiments, the steps ofuse CMYK printing. In some embodiments, the steps ofmay use a continuous printing path. In other cases, other methods, techniques, and/or processes may be used. In some embodiments, the steps ofmay be implemented using the system illustrated in. In other cases, other systems and/or devices may be used. It should be understood that additional and/or fewer steps may be used. The processes illustrated inare for illustrative purposes only.

In some embodiments, a base may be provided, as in step(see), to receive a three-dimensional structural component. In some embodiments, the base may be provided manually. Referring to, a human user may place baseonto platformof printing deviceto permit printing deviceto print directly onto base. As shown, the base may be an upper for an article of footwear. It should be understood that the base may be other articles as previously described. In other embodiments, the base may be provided automatically. For example, the placement of baseonto printing devicemay be automated using one or more loaders (not shown) to place base(or another substrate) onto printing device.

Some embodiments permit a customization of articles by facilitating a selection of a base from a set of bases. Referring to, a human user may select to print on first upper style, second upper style, or third upper styleusing input devices (e.g., keyboard and mouse). In the example, first upper stylemay have a corresponding first upper supply, second upper stylemay have a corresponding first upper supply, and third upper stylemay have a corresponding first upper supply. In the example, basemay be selected from first upper supplyaccording to the selection of first upper style. In other embodiments, other methods may be used to permit a customization of articles.

In some embodiments, a set of predetermined thicknesses for a three-dimensional structural component may be provided, as in step(see). In some embodiments, the set of predetermined thicknesses may be provided by a human user. Referring to, a human user, such as a customer or designer, may generate set of predetermined thicknessesaccording to personal preferences using computing system. It should be understood that in some embodiments, at least a portion of the set of predetermined thicknesses may be automatically generated by a computing device. In the example, computing systemmay transmit set of predetermined thicknessesto printing device, which may be locally connected to computing systemor may be remotely connected to computing systemusing network. In other embodiments, the set of predetermined thicknesses may be provided differently.

Generally, the set of predetermined thicknesses may have any suitable number of thicknesses to represent a shape of a three-dimensional structural component. In some embodiments, the set of predetermined thicknesses may include two thicknesses. Referring to, set of predetermined thicknessesmay include first thicknessand second thickness. As shown, first thicknessmay be less than second thickness. In other instances, second thickness may be less than or equal to first thickness (not shown). In some embodiments, the set of predetermined thicknesses may optionally include more than two thicknesses. Referring to, set of predetermined thicknessesmay optionally include third thickness. In other embodiments, the set of predetermined thicknesses may have more than three thicknesses.

In some embodiments, the printing device may be instructed, as in step(see) to print a single layer for the three-dimensional structural component using the set of predetermined thicknesses. The instructions may be in any suitable format and/or use any suitable topology. In some embodiments, the set of predetermined thicknesses may be converted to a three-dimensional printable file, such as a stereolithography file (STL file); in other cases, the set of predetermined thicknesses may be converted into a different design structure. In some embodiments, a set of predetermined thicknesses may use a digital image or image file. For example, a set of predetermined thicknesses may be an image file using a raster format, vector format, compound format, and/or stereo format. Examples of raster formats may include joint photographic experts group (JPEG), tagged image file format (TIFF), graphics interchange format (GIF), bitmap image file (BMP), portable networks graphics (PNG), and the like. Examples of vector formats may include computer graphics metafile (CGM), Gerber format (GERBER), scalable vector graphics (SVG), and the like. Examples of compound formats may include portable document format (PDF), encapsulated PostScript, PostScript, and the like. Examples of stereo format may include JPEG stereo (JPS), portable networks graphics (PSN), and the like. It should be understood that some image files may support multiple layers such that multiple sets of predetermined thicknesses may be stored in a single image file. In other embodiments, the instructions may be different.

In some embodiments, a first portion of a single layer for the three-dimensional structural component may be printed, as in step(see), onto the base so that the first portion has the first thickness. Referring to, printing devicemay dispense print materialin a liquid state onto base. In the example, curing devicemay emit ultraviolet lightonto baseto cure first portionof single layer. In other embodiments, the first portion may be printed differently.

In some embodiments, the printing device may move the printhead assembly in a single pass for printing different portions of a single layer. Referring to, printing devicemay move printhead assemblyin single passbetween first portionand second portion. In the example, the single pass may be from left edgeto right edge. In other instances, the single pass may be from the right edge to the left edge (not shown). In other embodiments, the printing device may print the first portion of the single layer using multiple passes (not shown).

In some embodiments, a separation distance between an upper surface of the base and the printhead assembly may remain constant during the step of moving the printhead assembly in the single pass. Referring to, printing devicemay move printhead assemblyparallel to upper surfacesuch that separation distancebetween upper surfaceand printhead assemblyremains constant during single pass. In other embodiments, the separation distance may vary during the step of moving the printhead assembly in the single pass (not shown).

Generally, the separation distance between an upper surface of the base and the printhead assembly may be any suitable distance. In some embodiments, the separation distance may be a predetermined printing parameter corresponding to the printing device. In some embodiments, the separation distance may be a design parameter determined by a human user. For example, the separation distance may be a printing step size to achieve a desired surface profile. In some embodiments, the separation distance may be automatically determined by software. For example, the separation distance may be a printing step size determined according to a received surface profile.

In some embodiments, the printing device may print the first portion of the single layer during the single pass. In some embodiments, printing the first portion of the single layer may include dispensing print material in a liquid state from the printhead assembly onto the base during the single pass. Referring to, printhead assemblymay dispense print materialin a liquid state from printhead assemblyonto baseduring single pass. In some embodiments, printing the first portion of the single layer may include curing the first portion of the single layer during the single pass. Referring to, printhead assemblymay emit ultraviolet lightonto baseto cure first portionof single layerduring single pass. In other embodiments, the printing device may print the first portion of the single layer using additional and/or fewer steps.

In some embodiments, a separation distance between an upper surface of the base and the printhead assembly may remain constant during the step of printing the first portion of the single layer. Referring to, printhead assemblymay dispense print materialusing separation distancebetween upper surfaceand printhead assembly. In the example, curing devicemay emit ultraviolet lightonto baseto cure first portionof single layerusing separation distance. In other embodiments, the separation distance may vary during the step of printing the first portion of the single layer (not shown).

In some embodiments, a second portion of a single layer for the three-dimensional structural component may be printed, as in step(see) onto the base so that the second portion has the second thickness. Referring to, printing devicemay dispense print materialin a liquid state onto base. In the example, curing devicemay emit ultraviolet lightonto baseto cure second portionof single layer. In other embodiments, the second portion may be printed differently.

In some embodiments, the printing device may print the second portion of the single layer during the single pass. In some embodiments, printing the second portion of the single layer may include dispensing print material in a liquid state from the printhead assembly onto the base during the single pass. Referring to, printhead assemblymay dispense print materialin a liquid state from printhead assemblyonto baseduring single pass. In some embodiments, printing the second portion of the single layer may include curing the second portion of the single layer during the single pass. Referring to, printhead assemblymay emit ultraviolet lightonto baseto cure second portionof single layerduring single pass. In other embodiments, the printing device may print the second portion of the single layer using additional and/or fewer steps.

In some embodiments, the printing device may print an amount of print material based on the set of predetermined thicknesses. Referring to, printing devicemay print first portionto a shorter height than second portionby dispensing a smaller volume of print material for first portionthan second portion. In the example, printing devicemay dispense print materialto print first portion, which has a smaller volume than print material, which is used to print second portion. That is, a volume of a print material printed for a portion of a layer may be selected to achieve a height of the set of predetermined thicknesses. In other embodiments, the printing device may print different thicknesses of a single layer using different methods.

In some embodiments, a separation distance between an upper surface of the base and the printhead assembly may remain constant during the step of printing the second portion of the single layer. Referring to, printhead assemblymay dispense print materialusing separation distancebetween upper surfaceand printhead assembly. In the example, curing devicemay emit ultraviolet lightonto baseto cure second portionof single layerusing separation distance. In other embodiments, the separation distance may vary during the step of printing the second portion of the single layer (not shown).

Generally, any suitable number of portions may be printed onto a base to achieve any suitable shape of the single layer for the three-dimensional structural component. In some embodiments, such shapes may have a stepped surface (see). In some embodiments, such shapes may have a surface having a linear slope such as a constant increase or decrease in thickness for the three-dimensional structural component (see). In some embodiments, such shapes may have a surface having a non-linear slope such as a gradually increasing or decreasing of a rate of change to a thickness (see).

In some embodiments, a third portion of a single layer for the three-dimensional structural component may be optionally printed onto the base so that the third portion has a third thickness of the set of predetermined thicknesses. Referring to, printing devicemay dispense print materialin a liquid state onto base. In the example, curing devicemay emit ultraviolet lightonto baseto cure third portionof single layer. It should be understood that an additional or fewer number of portions of the single layer may be used to form any suitable shape. In other embodiments, the third portion may be printed differently.